Underground Belt Structure

Flex PAL Series (CEMA C & D)

Interchangeable
The new Cat Flex PAL Series is designed to work seamlessly with existing underground bulk-material conveyor systems. The retrofit design allows for easy integration with major competitive underground structure configurations. With a wide range of product compatibility, the Flex PAL series makes upgrading equipment effortless. Triple-tested with a standard three-years-to-life warranty, Flex PAL offers quality and performance assurance for your mining operations unsurpassed in the industry.

Roof-Hung Structure
This typical 10-foot section of roof-hung structure features the Cat handle and pin rail connections for quick installation. No special tools are required to set up.

Floor-Mounted Structure
The example of floor-mounted handle & pin structure shows the return rolls mounted in drop brackets attached to the channel rails. Return rolls can also be mounted in the floor stands.

Wire-Rope Structure
The Cat wire-rope structure features carrying idlers with mounting feet that cradle the wire rope until securely fastened with the supplied hardware. The tie-off stands can be floor-mounted or roof-hung, as shown on page 7 of this brochure.
2

Cat Carrying Assemblies

Cat carrying idlers have a single mechanical tube crossmember, sized to handle full capacity loading through 60 in belt widths. Box frame carrying idlers are also available.

Cat steel rolls going through an automated five-stage assembly and testing process.

Carrying Idler Assemblies for Channel Mount

4 in - 35 - 7Ga. - CEMA C or D Carrying Assembly*

Belt Width
30 36 42

Part No. CEMA C CEMA D

865813 865814 865815

D
8 ft 3/4 in

E
1 ft 7/8 in

41 ft 1/4 in 31 ft 5/16 in 12 ft 1/4 in

47 ft 1/4 in 35 ft 13/16 in 14 ft 1/4 in 10 ft 5/16 in 1 ft 7/8 in 53 ft 1/4 in 42 ft 11/16 in 16 ft 1/4 in 10 ft 9/16 in 1 ft 7/8 in

5 in - 35 - 7Ga. - CEMA C or D Carrying Assembly*

Belt Width
36 42 48 54

Part No. CEMA C CEMA D

865816 865770 865736 865817 865823 865824 865825

E
2 ft 3/8 in 2 ft 3/8 in 2 ft 1/16 in 2 ft 1/16 in

47 ft 1/4 in 35 ft 3/16 in 14 ft 1/4 in 10 ft 3/4 in 53 ft 1/4 in 42 ft 1/8 in 16 ft 1/4 in 65 ft 1/4 in 51 ft 15/16 in 20 ft 1/4 in 11 ft 13 ft 3/8 in 59 ft 1/4 in 46 ft 11/16 in 18 ft 1/4 in 12 ft 1/4 in

6 in - 35 - 7Ga. - CEMA C or D Carrying Assembly*

Belt Width
36 42 48 54 60

Part No. CEMA C CEMA D

865818 865819 865820 865821 865822 865826 865827 865828 865829

E
2 ft 7/8 in

47 ft 1/4 in 34 ft 9/16 in 14 ft 1/4 in 11 ft 1/8 in

53 ft 1/4 in 41 ft 5/8 in 16 ft 1/4 in 11 ft 7/16 in 2 ft 7/8 in 59 ft 1/4 in 46 ft 1/8 in 18 ft 1/4 in 12 ft 5/8 in 2 ft 9/16 in 65 ft 1/4 in 51 ft 3/8 in 20 ft 1/4 in 13 ft 13/16 in 2 ft 9/16 in 71 ft 1/4 in 56 ft 5/8 in 20 ft 1/4 in 14 ft 15/16 in 2 ft 9/16 in

*Available with 1/4 in wall rolls upon request.

Carrying idler for channel structure

Carrying Idler Assemblies for Wire-Rope Mount

4 in - 35 - 7Ga. - CEMA C or D Carrying Assembly*
Belt Width

Part No. CEMA C CEMA D

865831 865832 865833

A
42 in 48 in 54 in

E
2 ft 1/4 in

30 36 42

31 ft 5/16 in 12 ft 1/4 in 9 ft 1/8 in

35 ft 13/16 in 14 ft 1/4 in 10 ft 11/16 in 2 ft 1/4 in 42 ft 11/16 in 16 ft 1/4 in 10 ft 15/16 in 2 ft 1/4 in

5 in - 35 - 7Ga. - CEMA C or D Carrying Assembly*

Belt Width

Part No. CEMA C CEMA D

865834 865835 865836 865837 865843 865844 865845

A
48 in 54 in 60 in 66 in

E
2 ft 3/4 in 2 ft 3/4 in

36 42 48 54

35 ft 3/16 in 14 ft 1/4 in 11 ft 1/8 in 42 ft 1/8 in 16 ft 1/4 in 11 ft 3/8 in 51 ft 15/16 in 20 ft 1/4 in

46 ft 11/16 in 18 ft 1/4 in 12 ft 5/8 in 2 ft 7/16 in 13 ft 3/4 in 2 ft 7/16 in

6 in - 35 - 7Ga. - CEMA C or D Carrying Assembly*

Belt Width
36 42 48 54 60

Part No. CEMA C CEMA D

865838 865839 865840 865841 865842 865846 865847 865848 865849

A
48 in 54 in 60 in 66 in 72 in

E
3 ft 1/4 in 2 ft 15/16 in

34 ft 9/16 in 14 ft 1/4 in 11 ft 1/2 in 46 ft 1/8 in 18 ft 1/4 in 13 ft

41 ft 5/8 in 16 ft 1/4 in 11 ft 13/16 in 3 ft 1/4 in 51 ft 3/8 in 20 ft 1/4 in 14 ft 3/16 in 2 ft 15/16 in 56 ft 5/8 in 22 ft 1/4 in 15 ft 5/16 in 2 ft 15/16 in

*Available with 1/4 in wall rolls upon request.

Cat EXALON Rolls

Another perfect choice for underground mining operations
In addition to our world-class steel rolls, Caterpillar offers a highly successful range of CEMA C-, D- and E-class rolls made of a proprietary high molecular weight polyethylene (HMWPE) called EXALON. While steel rolls are effective in most bulk-material handling applications, some applications benefit from the use of the EXALON roll product. Applications with environments that are highly corrosive, abrasive, wet or have a tendency for material buildup on the roller are ideal for the EXALON roll and its additional features and benefits.

EXALON Benefits at a Glance

MSHA certified
Certified for underground use: IC-56/1 flame resistant and IC-56/2 flame resistant and static dissipating.

Longer shell life

EXALON rolls last two to three times longer than steel rolls in highly corrosive and/or highly abrasive environments.

Flex PAL Center EXALON Design Features:

 Center roll subject to most frequent replacement most wear of the three rolls  Helps reduce the frequency of replacing the center idler roll with EXALON  The EXALON rolls shell life can be two to three times longer than a steel rolls

Low maintenance
Cat Idler PAL ensures life-long grease management.

Reduced belt damage

The smooth PE surface minimizes belt friction and wear and acts as a slider bar in the event of a bearing seizure. The all-PE body means there are no sharp pizza cutter edges.

Smooth operators
Tube-based with higher concentricity further enhanced by final machining (poly-body) for reduced belt wear, the EXALON roll offers balanced, vibration-free running. These fully conductive rolls are MSHA-certified as safe for underground use. They have two certifications: IC-56/1 flame-resistant and IC-56/2 flame-resistant and static-dissipating.

Lighter weight
EXALON rolls are 20-30% lighter than equivalent steel rolls.

Corrosion-proof
Being made of HMWPE, the EXALON roll is not subject to corrosion.

Sound dampening
Reduce noise by up to 20%, particularly in underground applications.

Versatile, low-maintenance
EXALON rolls can be retrofitted to any frame even those of competitors. Custom sizes can be ordered for special applications. EXALON heads are installed using a unique spin-welding method, creating a single-piece roll construction. Cat Idler PAL (Positive Automatic Lubrication) ensures life-long grease management, making them virtually maintenance-free.

Resistance to material buildup

The smooth, non-adhesive HMWPE surface resists material buildup.

Cost-efficient
EXALON offers cost savings through extended life, reduced downtime, longer replacement intervals and reduced belt damage.

Tested for quality

All Cat rolls EXALON and steel are processed through an automated assembly system that tests and records rotational torque, total indicator run-out and axial end play. Upon acceptance, each idler roll is permanently marked with a serial number and date of manufacture.

Versatile
The entire EXALON product line can be produced to fit any existing manufacturers top-side and return frame assemblies.

Handle & Pin Roof-Hung Spreader Assemblies

Handle & Pin Adjustable Floor Stand Assemblies

3 in Channel Spreader

Belt Width
30 36 42

Part No.
603895 603896 603897

A
41 ft 1/4 in 47 ft 1/4 in 53 ft 1/4

3 in Channel Floor Stand

Belt Width
30 36 42

Part No.
865914 865915 865916

A
41 ft 1/4 in 47 ft 1/4 in 53 ft 1/4 in

B
42 ft 5/8 in 48 ft 5/8 in 54 ft 5/8 in

4 in Channel Spreader

Belt Width
42 48 54 60

Part No.
603898 603899 865739 865740

A
53 ft 1/4 in 59 ft 1/4 in 65 ft 1/4 in 71 ft 1/4 in

4 in Channel Floor Stand

Belt Width
42 48 54 60

Part No.
865917 865918 865919 865920

A
53 ft 1/4 in 59 ft 1/4 in 65 ft 1/4 in 71 ft 1/4 in

B
54 ft 5/8 in 60 ft 5/8 in 66 ft 5/8 in 72 ft 5/8 in

Handle & Pin Side Rails

Channel Slider/Hanger Brackets

Slider/Hanger Brackets

Part No.
603556 603557

Channel Size
3 in CHANNEL 4 in CHANNEL

3 in Channel Rail

Part No.
865851 603890 865852

A
7 ft-11 ft 3/4 in 9 ft-11 ft 3/4 in 11 ft-11 ft 3/4 in

B
3 in 3 in 3 in

C
3 ft 7/16 in 3 ft 7/16 in 3 ft 7/16 in

Roof Mounting Plates for Chain Hung Structure

Roof Plates
Part No. A
3/4 in 1 in 1 ft 1/4 in 1 ft 1/2 in

4 in Channel Rail

6

Part No.
865853 603677 865854

A
7 ft-11 ft 3/4 in 9 ft-11 ft 3/4 in 11 ft-11 ft 3/4 in

B
4 in 4 in 4 in

C
3 ft 7/16 in 3 ft 7/16 in 3 ft 7/16 in

223140 246787 213551 242648

Return Roll Assemblies

Cat Standard Chain

4 in - 7Ga. Return Roll*

1/4 Proof Coil Chain with Hook

5/16 Proof Coil Chain without Hook

A
39 in 45 in 51 in

Part No.
208650 244458 231598

A
4 ft 5 ft 6 ft

Part No.
222516 216997

A
5 ft 6 ft

Belt Width
30 36 42

Part No. CEMA C CEMA D

326506 326507 326508

Channel Mounted Drop Brackets

3 in Brackets
Part No. 865670 865855 865856

5 in - 7Ga. Return Roll*

Belt Width
36 42 48 54

Part No. CEMA C CEMA D

326563 326564 326565 326566 326665 326666 326668 326669

A
45 in 51 in 57 in 63 in

A
9 in 12 in 16 in

4 in Brackets 6 in - 7Ga. Return Roll*

Part No. A
45 in 51 in 57 in 63 in 69 in 865671 865857 865858

A
9 in 12 in 16 in

Belt Width
36 42 48 54 60

Part No. CEMA C CEMA D

326609 326611 326612 326613 326614 326780 326781 326782 326783 326784

Wire Rope Drop Brackets

3 in Brackets
Part No.
884029 865911 865912

*Available with 1/4 in wall rolls upon request.

A
9 in 12.75 in 16.5 in

Wire-Rope Adjustable Tie-Off Assemblies

Tie-Off Stands
Part No.
276956 271136

A Min.
24 in 32 in

A Max.
36 in 48 in

Underground Belt Structure Flex Pal Series (CEMA C & D)

For more complete information on Cat products, dealer services, and industry solutions, visitus on the web at mining.cat.com and www.cat.com 2011 Caterpillar Inc. All rights reserved Materials and specifications are subject to change without notice. Featured machines in photos may include additional equipment. See your Cat dealer for available options. CAT, CATERPILLAR, their respective logos, Caterpillar Yellow and thePower Edge trade dress, as well as corporate and product identity used herein, aretrademarks of Caterpillar and may not be used without permission. AEXQ0593